Transcript
UM10508 230 V (AC) 17 W LED driver and dimmer Demo board using the SSL2102 Rev. 1 — 7 April 2016
User manual
Document information Info
Content
Keywords
SSL2102, AC mains supply, dimmable LED driver, AC/DC conversion
Abstract
This User manual describes a demonstration (demo) board for evaluating an AC mains LED driver with a dimmer for 17 W, PAR38 LEDs using the SSL2102. It also describes key features and connections to aid the design of LED drivers for typical applications.
UM10508
Silergy Corp.
230 V (AC) 17 W LED driver/dimmer demo board using the SSL2102
Revision history Rev
Date
Description
v.1
20120116
first issue
UM10508
User manual
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Rev. 1 — 7 April 2016
2 of 15
UM10508
Silergy Corp.
230 V (AC) 17 W LED driver/dimmer demo board using the SSL2102
1. Introduction WARNING Lethal voltage and fire ignition hazard The non-insulated high voltages that are present when operating this product, constitute a risk of electric shock, personal injury, death and/or ignition of fire. This product is intended for evaluation purposes only. It shall be operated in a designated test area by personnel qualified according to local requirements and labor laws to work with non-insulated mains voltages and high-voltage circuits. This product shall never be operated unattended.
This user manual describes a demo board for evaluating an AC mains LED driver with a dimmer for 17 W, PAR38 LEDs using the SSL2102. It describes key features and connections to aid the design of LED drivers for typical applications. The demo board operates from an AC mains voltage of 230 V (AC) at 50 Hz. The resulting design is a trade-off between high-power factor, efficiency and dimmer compatibility, combined with high output stability and ElectroMagnetic Compatibility (EMC) compliance.
2. Safety Warning The demo board is powered by AC mains voltage. Avoid touching the board when power is applied. An isolated housing is obligatory when used in uncontrolled, non-laboratory environments. The secondary circuit with LED connection has galvanic isolation, however this isolation is not in accordance with any standard and has not been thoroughly tested. Always provide galvanic isolation of the mains phase using a variable transformer. The following symbols identify isolated and non-isolated devices.
019aab173
a. Isolated Fig 1.
UM10508
User manual
019aab174
b. Non-isolated
Isolated and non-isolated symbols
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Silergy Corp.
230 V (AC) 17 W LED driver/dimmer demo board using the SSL2102
3. Specification Table 1.
Demo board specification
Parameter
Value
Comment
AC line input voltage
210 V (AC) to 230 V (AC), 10 %, 50 Hz 230 V (AC) model
Output voltage (LED voltage)
17 V (DC) to 33 V (DC)
Output voltage protection
33 V (DC)
Output current (LED current)
500 mA typical
Input voltage and load current dependency
5 % to +5 %, between 210 V (AC) and 250 V (AC)
Output voltage and load current dependency
10 % to +10 %, between 19 V (DC) to 30 V (DC)
Temperature stability
3 % to +3 % from 20 C to +100 C
Current ripple
15 % at 500 mA
typical value
Maximum output power (LED power)
19 W
depends on load
Efficiency
78 % to 82 %
Power factor
>0.93 at 230 V (AC)
Switching frequency
40 kHz to 60 kHz
at 230 V (AC) input voltage
Dimming range
100 % to 0 %
for triac dimmers
Board dimensions
82 mm 62 mm 35 mm
LBH
Operating temperature
0 C to 105 C
-
EMC Compliance
FCC15 and IEC 61000-3-2 pre-compliant EN 55015 and IEC 61000-3-2 pre-compliant
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Rev. 1 — 7 April 2016
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230 V (AC) 17 W LED driver/dimmer demo board using the SSL2102
a. Top view.
b. Bottom view. Fig 2.
UM10508
User manual
17 W PAR38 LED demo board
Silergy Corp. Confidential - Prepared for Customer Use Only.
Rev. 1 — 7 April 2016
5 of 15
UM10508
Silergy Corp.
230 V (AC) 17 W LED driver/dimmer demo board using the SSL2102
4. Demo board connections The demo board is optimized for an AC mains source of 120 V (60 Hz). It is designed to work with multiple high-power LEDs having a total working voltage of between 18 V and 33 V. The output current is set to 600 mA at typical load. The output voltage is limited to 33 V. When attaching an LED load to the board (hot plugging), an inrush peak current occurs due to the discharge of output capacitors C9 and C10. Frequent discharges can damage or deteriorate the LEDs. Remark: Mount the board in a shielded or isolated box for demonstration purposes.
dimmer
L
AC mains
019aaa550
Fig 3.
Demo board connections
Place a galvanic isolated transformer between the AC source and the demo board, if one is used. Connect a series of between 5 and 10 LEDs to the output as shown in Figure 3.
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Rev. 1 — 7 April 2016
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UM10508
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230 V (AC) 17 W LED driver/dimmer demo board using the SSL2102
5. Dimmer compatibility Silergy Corp. has tested the performance of several triac-based dimmers having different specifications. The range of dimmers which have been tested with the demo board are given in Table 2. Table 2. Tested dimmers An incandescent lamp is used as load. Manufacturer
Type
Voltage (V) Power range (W)
Trigger High dim level (%)
Low dim level (%)
LK
DG07103
230
400
[1]
91.5
6.5
Italy
DG04027
220 to 240
60 to 400
[1]
90
3
60 to 500
[1]
88
13
40 to 300
[1]
97
1.5
BG_British Legrand
220
JingNeng
JN2301
230
50 to 400
80
0.5
Meierte
PDDT
230
630
[1]
98
0.2
300
[1]
96
0
450
[2]
89
7.5
92.5
15
90
8.7
CLIPSAL
User manual
V8051
200 to 250
[1]
ShiToneSB
UM10508
BG general
DIM
230
32E450UDM 220 to 240
Busch-Jaeger Elektro 6513 U-102
230
40 to 420
[2]
HPM
230 to 240
10 to 700
[2]
[1]
Leading edge.
[2]
Trailing edge.
CAT700T
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230 V (AC) 17 W LED driver/dimmer demo board using the SSL2102
6. Functional description Refer to Figure 4 “Demo board 230 V (AC) schematic” on page 12 for more information. The AC mains LED driver IC SSL2102 controls and drives a flyback converter circuit and ensures correct dimmer operation. The IC has three integrated high-voltage switches, one of which, located between pins DRAIN and SOURCE, controls flyback input power. When the switch opens, current flows and is stored as energy in transformer TX1. The current is interrupted when either:
• the duty factor exceeds the 75 % maximum level set using the PWMLIMIT pin • the voltage on the SOURCE pin exceeds 0.5 V In the next cycle, the energy stored in the transformer discharges via D6 to output capacitors C9 and C10. The load absorbs the energy. The external RC components connected to pins RC and RC2 control the internal oscillator timing. These external components set the flyback converter frequency. The upper and lower frequency values are set using the BRIGHTNESS pin. The ratio between R11 and R12 sets flyback converter frequency range. The two other switches in the IC are called weak-bleeder (pin WBLEED) and strong-bleeder (pin SBLEED). When the voltage on these pins is below a certain value, typically 52 V, the strong-bleeder switches on. A path is provided for the load current to the dimmer during zero voltage crossing. The dimmer timer is reset. When the voltage on the pins is above 52 V and the voltage on pin ISENSE > 100 mV, transistor Q3 switches the weak-bleeder on. The weak-bleeder supplies a boosted (hold) current to the dimmer to maintain stable latching when the flyback converter draws insufficient current. Figure 4 shows the bleeder voltage against time in dimmed and undimmed modes. The demo board is optimized to work at a power factor above 0.9. The flyback converter operates during the MOSFET on-time. Capacitors C9 and C10 buffer the flyback converter output power. This configuration gives the circuit a resistive input current behavior in undimmed mode; see curve II in Figure 4. In dimmed mode, the dimmer latch and hold current must be maintained. In addition, add a damper to reduce the inrush current and dissipate the electric power stored in the dimmer LC filter. A serial resistor is used as a damper at power ranges of less than 10 W. However, a resistor is inefficient at higher power ranges. This effect is due to the significant voltage drop and dissipation that occurs from the supply current to the flyback converter. The Darlington transistor Q4 provides the necessary high gain. Q4 is saturated while its base voltage is higher than the emitter voltage plus the base-emitter voltage (VBE). The voltage across emitter resistor R14 increases with the current. When the emitter voltage rises above the threshold, Q4 stops saturation, turns off and R15 limits the current. Choose the values of D9 and R13 with care to ensure consistent operation. A Darlington transistor provides the necessary high current gain. This modification changes the specifications of efficiency and power factor.
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230 V (AC) 17 W LED driver/dimmer demo board using the SSL2102
A combination of serial resistance and a parallel damper is chosen. The serial resistance comprises R14, R15 and R17. The parallel group damper comprises C1, C13 and R1 in parallel with C8 and R7 for optional fine-tuning. To improve efficiency, the major serial damping is activated only when there is a peak inrush current (active inrush current limiter). In normal operation, the Darlington transistor Q4 conducts, bypassing R15 and lowering ohmic losses. When a high inrush current is detected, Q4 starts to clip at its maximum current of 500 mA. The flyback converter input circuit must have a filter that is partially capacitive. C2, L2, C3, C13 and L1 form a filter that blocks most of the disturbance caused by the flyback converter input current. The drawback of this filter is a reduced power factor due to the capacitive load. A lower flyback converter power relative to the capacitive value of this filter/buffer reduces the power factor. With the 230 V (AC) design using 330 nF capacitors, a minimum power factor of 0.93 is achieved. The demo board has a feedback loop to limit the output current. The feedback loop senses the LED current through sense resistor R25, and current mirror circuit with IC4. The current level can be set using R27 and R29. The same feedback loop is also used for overvoltage protection. If the LED voltage exceeds 33 V, a current starts to flow through R23 and D11. The current through the optocoupler IC3 forces pins PWMLIMIT and BRIGHTNESS LOW. At a value below 400 mV, the MOSFET on-time is zero. The feedback loop has a proportional action only. The gain is critical because of phase shift caused by the flyback converter and C6. The relationship between pin PWMLIMIT and the output current is quadratic in nature. The resulting output current spread is acceptable for most LED applications. If higher demands are placed on LED current spread, a secondary regulation circuit in combination with an added pure current action control is advisable. The dimming range is detected by sensing the average rectified voltage. R2 and R10 form a voltage divider, and C4 filters the resulting signal. The flyback converter sets its duty factor and converter frequency accordingly.
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Rev. 1 — 7 April 2016
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230 V (AC) 17 W LED driver/dimmer demo board using the SSL2102
7. System optimization The modifications described in this section can be applied to achieve customer application specifications.
7.1 Changing output voltage and LED current One of the major advantages of a flyback converter over other topologies is its suitability for driving different output voltages. In essence, changing the winding ratio while maintaining the value of the primary inductance shifts the output working voltage accordingly. Part of the efficiency of the driver is linked to the output voltage. A lower output voltage increases the transformation ratio and cause higher secondary losses. In practice, mains dimmable flyback converters have an efficiency of:
• 85 % for higher output power and voltage such as 60 V • 60 % for lower output power and voltage such as 1 W and 3 V At lower voltages, synchronous rectification is advisable to reduce losses after high current is rectified. Silergy Corp. TEA1761 and TEA1791 synchronous rectification controllers are ideal for this purpose. Calculations for transformer properties and peak current are described in detail in application note AN10754, SSL2101 and SSL2102 dimmable mains LED driver.
7.2 Changing the output ripple current The LED voltage, The LED dynamic resistance and the output capacitor determine the output ripple current. While the values of C9 and C10 are chosen to optimize capacitor size with light output. A ripple of 15 % results in an expected deterioration of LED brightness of less than 1 %1. The size of the buffer capacitor is determined using Equation 1. I led 1 C10 + C9 = -------- ------------------------------------ I 6 f net R dyn
(1)
Example: A 5 % ripple current, a 50 Hz AC mains frequency and a 0.6 dynamic resistance, 20 results in a combined C9 + C10 value of ---------------------- = 111 mF . 300 0.6 A ripple current of 25 % and a dynamic resistance of 6 , results in a value for C9 + C10 4 of ---------------------- = 2200 F . 300 6 Using a series of LEDs, the dynamic resistance of each LED can be added to the total dynamic resistance.
1.
M. Weiland 28-07-2006
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230 V (AC) 17 W LED driver/dimmer demo board using the SSL2102
7.3 Adapting to high-power reverse phase transistor dimmers Reverse phase (transistor) dimmers differ in two ways that can be beneficial:
• Due to the negative phase, there is no inrush current when the dimmer triggers. Using triac dimmers, there is a sudden voltage difference over the input, resulting in a steep charge of the input capacitors. The resulting peak current results in higher damper dissipation. Using transistor dimmers, the steep charge is missing. The input capacitors are less stressed and the input circuit is less prone to audible noise.
• Transistor dimmers contain active circuitry that requires a load charge while the dimmer is open. To avoid internal dimmer losses, the dimensioning of the internal supply voltage generation circuit is critical. This means that the remaining voltage drop across the lamp must be low enough to allow this charge to be reached. The minimum load to achieve such a low voltage drop results in inefficient operation at low output power levels. The cause of which is that most of the energy is wasted driving the dimmer instead of used to producing light. The weak-bleeder resistor values of R3 and R4 are chosen to ensure that any losses are within acceptable limits. These losses only occur in dimmed mode at the end of the phase. The voltage drop in some transistor dimmers is not sufficient for full control of the dimming range. The SSL2102 senses the dimming range by taking the average rectified voltage as input. To compensate for the reduced voltage difference, the voltage detection can be made more sensitive by placing a Zener diode in series with R2. The dimming curve is steeper and shifted when using triac dimmers because of increased sensitivity.
7.4 Changing the output current The output current can be set initially by varying the values of R29 and R27. The power section and transformer train can withstand output currents up to 500 mA, but losses increase at higher current levels. Resistors R19A/R19B limit the primary peak current and consequently the maximum output power.
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R1 2.2 kΩ 2W
RGND [1] -
C1 100 nF 400 V
BD1
C2 0.1 μF 400 V
D1 n.c.
VACT [1]
Q3
D5
R2 4.7 kΩ/2 W 10 kΩ/10 kΩ
R9 200 kΩ
DRAIN
SBLEED
R11 8.2 kΩ
GND GND
WBLEED
5 6 7 8 9
R12 100 kΩ
RGND [1]
+ C10 1m F 35 V
C9 1m F 35 V
N4, N5
-
GND
VCC
GND
GND
SOURCE
GND
GND
BRIGHTNESS RC2
AUX ISENSE
SSL2102
10
RC
PWMLIMIT
8 R19A n.c.
16 15 14 12 11
Q4 D9 ZD4V3 R14 3.3Ω 30 Ω/30 Ω/30 Ω
NPN
R18 100 kΩ
VCC [1]
D8 ZD33V
C7 4.7 nF
R30 0Ω
D10
R22 10 Ω R20 1 kΩ
D7 + C8 10 μF 50 V
IC3-B 4
+
o
2
1
C12 100 μF 16 V
3
4
N3
IC4 BCM61B R32 1 kΩ
SGND
SGND
5
C11 2.2 nF 4 kV SGND
R17 R15 10 Ω 330 Ω 680 Ω/680 Ω 20 Ω/20 Ω
aaa-001767
12 of 15
UM10508
Some resistor values are shown with format x/x/x which represent the values required of resistors connected in parallel.
Demo board 230 V (AC) schematic
R29 3.9 kΩ
R31 1 kΩ
(1) Optional.
Fig 4.
R27 39 kΩ
R26 10 kΩ
R21 100 kΩ
R16 200 kΩ C6 + 100 nF 63 V
TX1
R24 6.8 kΩ
R23 10 kΩ
D11 ZD33
R19 0.75 Ω
13
C5 330 pF
R14 0.22 Ω 0.25 W
SGND
o 3
20 19 18 17
IC3-A
R13 510 kΩ
diode04/05
230 V (AC) 17 W LED driver/dimmer demo board using the SSL2102
Rev. 1 — 7 April 2016
Silergy Corp. Confidential - Prepared for Customer Use Only.
1
2 GND 3 GND 4
R6 7.5 kΩ
VACT [1]
o 2
L3 100 μF
D6
6 o
N2 IC1
RGND [1]
+ C4 4.7 μF
1 N1
VCC [1]
R10 12 kΩ
D4 180 V 3W
C8 n.c.
R4 7.5 kΩ/3 W 22 kΩ/22 kΩ/22 kΩ
R3 7.5 kΩ/3 W 22 kΩ/22 kΩ/22 kΩ
R8 30 kΩ
C3 0.1 μF 400 V
R7 n.c.
PNP-TO92
R2 1.5 MΩ
L1 fer coil
L2 680 μH
D3 BC1
+
Silergy Corp.
N
C13 2.2 nF 630 V
8. Demo board schematic
UM10508
User manual
L
UM10508
Silergy Corp.
230 V (AC) 17 W LED driver/dimmer demo board using the SSL2102
9. PCB components Table 3.
Demo board 230 V (AC) components
Reference
Quantity
Description
Part
Comment
BD1
1
bridge diode
DB107S
-
C1
1
100 nF; 400 V
CM150-5_6X12
EMI
C2; C3
2
Pi-filter; 0.1 F; 400 V
CM150-5_6X18
-
C4
1
VCTRL > 105C; 4.7 F; 50 V
CAL04/5
-
C5
1
Cosc; 330 pF; 0805C
-
-
C6
1
330 nF; 50 V
CAL04/5
active damper on
C7
1
4.7 nF; 0805C
-
WBLEED on; noise
C8A
1
VCC > 105 C; 10 F; 50 V
CAL04/5
-
C9; C10
2
1 mF; 35 V; > 105 C; ECOUT
-
C11
1
Y-capacitor; 2.2 nF; 400 V
-
C12
1
100 F; 16 V
CAL04/5
time control CC_OCP on
C13
1
2.2 nF; 630 V
CM150-5_6X12
EMI
D1
0
Zener diode; 250 V
P6KE250
-
D3
1
diode; 02/10
HER107
-
D4
1
Zener diode; 180 V; 3 W; DIP2
BZT030180
-
D5
1
diode; DIP2
HER107
-
D6
1
diode; DIP2
HER303
-
D7
1
diode; SO8
IN4148
-
D8
1
Zener diode
ZD33V
-
D9
1
Zener diode; 4.3 V; SMD; SOD80
-
-
D10
1
diode; SO8
IN4148
-
D11
1
Zener diode
ZD33V
-
IC1
1
IC; SO20
SSL2102
-
IC3
1
optocoupler; IC04-10/PC
LTV-817B
-
IC4
1
current mirror
BCM61B
-
L1
1
EMI MHz level
FERCHOCK
W.E. BEAD
L2
0
WECHOCK; 680 H; SMD
-
-
L3
1
WECHOCK-2; 100 H; SMD
-
-
Q3
1
PNP transistor; TO92
KSP92
-
Q4
1
NPN transistor; TO220
ST901T
-
-
R1
3
6.8 k; R-POWER; 2.2 k; 2 W; SMD
-
three in parallel
R2
1
1.5 M; 5 %; 1206
-
tune for maximum on VCTRL
R3; R4
6
22 k; R-POWER; 15 k; 3 W; SMD
-
three in parallel
R5
2
10 k; R-POWER; 4.7 k; 2 W; SMD
-
two in parallel
R6
1
7.5 k; 0805
-
tune for dimming curve
R8
1
30 k; 1206
-
hold current compensation
R9
1
200 k; 1206
-
hold current compensation
R10
1
12 k; 0805
-
tune for minimum off VCTRL
R11
1
Cosc; 0805; 8.2 k
-
-
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230 V (AC) 17 W LED driver/dimmer demo board using the SSL2102
Table 3.
Demo board 230 V (AC) components …continued
Reference
Quantity
Description
Part
Comment
R12
1
100 k; 0805
-
R18 WBLEED on
R13
1
390 k; RT3.5MM-1W; DIP
-
DIP
R14
3
10 ; RT5MM; 3.3 ; 2 W; SMD
-
three in parallel
R15
2
680 ; RT5MM; 330; 2 W; SMD
-
two in parallel
R16
1
200 k; 0805
-
WBLEED on
R17
3
20 ; RT5MM; 10 ; 2 W; SMD;
-
two in parallel
R18
1
100 k; 0805
-
-
R19
1
0.75 ; 1 %; 1206
-
tune for Ipk;
R20
1
1 k; 0805
-
tune for dimming curve
R21
1
100 k; 0805
-
-
R22
1
10 ; 0805
-
VCC noise
R23; R26
2
10 k; 0603
-
tune for CC_OCP
R24
1
6.8 k; 0603
-
current limit
R25
1
0.22 ; 0.25 W; 1 %; DIP; RT3.5MM
-
DIP
R27
1
51 k; 0603
-
tune for CC_OCP
R29
1
3.9 k; 0603
-
tune for CC_OCP
R30
1
0; 0603
-
-
R31; R32
2
1 k; 0603
-
tune for CC_OCP
TX1
1
transformer; 1 mH; EFD25-DIP
Würth Elektronik
-
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230 V (AC) 17 W LED driver/dimmer demo board using the SSL2102
10. Test results 10.1 Input and output stability Table 4.
UM10508
User manual
Input and output stability test results
No. Board VIN (V (AC))
PI (W)
PF
Vo (V)
Io (A)
Po (W)
(%)
1
230
17.87
0.936
29.1
0.503
14.6373
81.9099
2
230
17.56
0.932
29
0.487
14.123
80.42711
3
232
17.79
0.933
29
0.495
14.355
80.6914
4
230
17.25
0.938
29
0.489
14.181
82.2087
5
232
17.79
0.933
29.1
0.499
14.5209
81.62395
6
229
17.48
0.943
29
0.493
14.297
81.79062
7
229
17.45
0.934
29
0.499
14.471
82.92837
8
229
17.48
0.934
29
0.492
14.268
81.62471
9
230
17.48
0.935
29
0.493
14.297
81.79062
10
230
17.48
0.93
29
0.499
14.471
82.78604
11
231
17.56
0.928
29
0.497
14.413
82.07859
12
230
17.51
0.94
29
0.494
14.326
81.81611
13
232
17.25
0.943
29
0.487
14.123
81.87246
14
229
17.58
0.935
29
0.496
14.384
81.82025
15
229
17.21
0.92
29
0.484
14.036
81.55723
16
229
17.39
0.936
29
0.491
14.239
81.88039
17
231
17.68
0.932
29.1
0.501
14.5791
82.46097
18
231
17.67
0.934
29.1
0.498
14.4918
82.01358
19
229
17.56
0.939
29
0.496
14.384
81.91344
20
231
17.48
0.931
29
0.491
14.239
81.45881
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